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FeniX Induction Heaters
User's Manual
Heater 45 Turbo
Heater 60 Turbo
Heater 80 Turbo
by
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PLEASE READ USER'S MANUAL CAREFULLY BEFORE USING THE MACHINE!
Check all parts for any transport damage. Please contact your
dealer/carrier if there is any damage.
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Contents
Chapter Page
1 Safety Recommendations ........................................................... 4
2 General Informations ........................................................... 5
2.1 Applications ....................................................................... 5
2.2 Recomended Operating Environments ........................ 5
3 Technical Data ....................................................................... 6
4 Installation Of Mains Plug ........................................................... 7
5 Preparation For Use ........................................................... 8
6 Operation .................................................................................. 9
6.1 Control Pannel ........................................................... 9
6.2 Power Level ...................................................................... 9
6.3 Magnet Sensor ........................................................... 10
6.4 Operating Modes ........................................................... 10
6.4.1 Temperature Mode ............................................... 11
6.4.2 Time Mode ........................................................... 13
7 Overload Warning .................................................................................. 14
8 Coil Overheated Warning ..................................................................... 15
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1- Safety Recommendations
CAUTION!
• Because of magnetic field,people wearing medical devices like
pacemaker or hearing aid, mustn't be within 5 meters of the machine
during operation.
• Electronic equipments or wristwatches, may also be affected.
• Be sure base panel of the machine cooled down before carrying.
During the operation, base panel may get hot.
• Be sure heated workpiece is not touching to electric cables.
• Follow the instructions at all the time.
• Be certain that you choose correct voltage supply.
• Never operate the machine in explosion risk areas.
• Do not expose the machine to high humidity.
• Never operate the machine without a yoke in position.
• Wear heat resistant gloves to handle hot workpieces.
• Use proper handling equipment when lifting heavy workpieces.
• Do not bring metal objects near to the machine while operation.
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2- General Informations
2.1 Applications
FeniX induction heaters has been designed to heat bearings; moreover, other metal
workpieces that form closed circuit like bushings, flange couplings, shrink rings, pulleys and
gears can be heated. Except special orders, maximum teperature limited to 250 °C .
Caution!
• Generally bearings should not be heated over 110 °C(at an
ambient temperature of 20 °C.
• Exquisite bearings should not be heated over 70 °C, that may couse
damage on the bearing.
• Demagnetization will not occur if the machine unpluged or the
main switch is switched off during operation.
• When the machine operating, and the power is lost and
restored, please select one of the modes and operate the
machine for a while to do workpiece's demagnetisation.
2.2 Recomended Operating Environments
For proper use of the machine, the following chart provides important information
concerning the recommended operating environments, or operating conditions.FeniX
Induction heaters designed for indoor use only.
• Operating Temperature 0ºC to 40ºC
• Operating Humidity 5% to 90%
• Transport/Storage Temperature -20ºC to 60ºC
Warning!: Operating the machine outside of the recommended operating environment
may negatively impact the machine performance, may cause damage to the machine
and will void the warranty!
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3- Technical Data
Model Heater 45 Turbo Heater 60 Turbo Heater 80 Turbo
Power 3,6kVA 6.0kVA 12,2kVA / 7kVA
Voltage 220-240V 380-420V / *220-240V 380-420V / *220-240V
Current 15,6A 15A 31A
Frequency 50hz 50hz 50hz
Yokes
**7 X 7 X 230mm
10 X 10 230mm
25 X 25 X 230mm
45 X 45 X 230mm
**20 X 20 X 300mm
**30 X 30 X 300mm
40 X 40 X 300mm
**50 X 50 X 300mm
60 X 60 X 300mm
**20 X 20 X 430mm
**30 X 30 X 430mm
40 X 40 X 430mm
60 X 60 X 430mm
80 X 80 X 430mm
Heater Control Unit Microprocessor Microprocessor Microprocessor
Turbo Heating Yes Yes Yes
Maximum Bearing Weight 40kg 150kg 300kg
Maximum Workpiece Diameter 350mm 500mm 600
Minimum Workpiece Diameter 10mm 28mm 28mm
Magnet Sensor Yes Yes Yes
FeniX Induction Heater Mass 19kg 38kg 98kg
FeniX Induction Heater Diameters 380 X 200 X 286(mm) 440 X 220 X 379 (mm) 600 X 280 X 528 (mm)
Power Level 5 Levels 5 Levels 5 Levels
Digital Screen Yes Yes Yes
Time Control 0-100*** min. 0-100*** min. 0-100*** min.
Temperature Control 0-250*** ºC 0-250*** ºC 0-250*** ºC
Audio Warning Yes Yes Yes
Automatic demagnetization Yes Yes Yes
Carrying Bag **Yes No No
Warranty 2 years 2 years 2 years
* = If lower voltage is used, the power will be reduced.
** = Optional
*** = Can increase.
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4- Installation Of Mains Plug
Be assured that the voltage supply is correct before operating the machine. Because of
many different types of mains plugs, no mains plug is supplied with bigger than heater 45
machines. A qualified electrician must install a suitable mains plug. The correct supply
voltage is 380V for Heater 60 Turbo and Heater 80 Turbo. For Heater 45 Turbo, the correct
supply voltage is 220V.
THIS PRODUCT SHOULD BE INSTALLED BY A QUALIFIED
TECHNICIAN,ELECTRICIAN OR ELECTRICAL MAINTENANCE
PERSON FAMILIAR WITH ITS OPERATION AND HAZARDS
INVOLVED!
The wires should be connected as follows:
220V
Phase Black
Neutral Brown
Ground Yellow / Green
380V
T1 (Phase) Black
T2 (Phase) Brown
Ground Yellow / Green
Recommended line protection: 40 A fuse rating for Heater 80 Turbo
16 A fuse rating for Heater 45 Turbo and Heater 60 Turbo
CAUTION!: Verify that the right fuse is installed.
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5- Preparation For Use
• Remove the machine from the box or the bag.
• Locate the machine in the horizontal position on a stable surface.
• Connect the mains plug to outlet.
• For best performance, place the workpiece to turbo's centre to do operation in
Turbo Mode.
• Use the largest yoke so that it completely covers the top of both vertical supports.
• Max Tempereture should be 150 ºC on turbo mode.
Turbo heating Standard heating
• For workpieces, that won't fit over the turbo, follow that step:
• Choose the one of the yokes that fit through the internal diameter of the workpiece
perfectly.
• Be sure, bright underside of the yoke resting evenly on the two vertical supports of
the machine.
• If you will use Temperature Mode, be sure that magnet sensor plugged to the
connector. Place the magnet sensor on the inner ring of the bearing or on the
innermost surface of the workpiece. If you will not connect the temperature probe
to connector, you will see “TEMP SENSOR NOT CONNECTED!” message on the
screen after few seconds then the machine will turn back to main menu.
• If you will use Time Mode, you do not have to connect the magnet sensor to
connector but we highly recommend to connect the temperature probe to check
workpiece's temperature.
• Turn on the main switch. (For Heater 45 Turbo, Heater 60 Turbo)
WARNING! : Heating high conductivity metals like copper, brass and aluminium on
turbo mode may damage the machine!
CAUTION! : If you will operate Heater 60 and Heater 80 continuously with 20x20mm
and 30x30 mm yokes, operate the machine with 220V voltage supply.
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6- Operation
6.1 Control Pannel
1
LCD Screen
2
Power Level Button
3
Temperature Mode Select Button
4
Time Mode Select Button
5
Up
6
Down
7
On/Off
6.2 Power Level selection
You can operate the machine in five different power levels. Pressing button 2 will change
the percentage of the power. During operation, most of the heat will be generated in the
inner side of bearing then the heat will be transferred through the bearing. Because of
that, It is so much important that bearings with small internal clearance or slight preload
are heated slowly. Slow heating avoids possible cause of damage to bearing. There is
many factors that can affect the amount of time required to heat a bearing such as
shape size and internal clearances.
• For sensitive (C1 – C2 clearance) bearings do not exceed 60% power.
• When using the small yoke, never exceed 60% power.
• In the case of overload, the machine will control the current automaticly.
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6.3 Magnet Sensor
• Always use magnet sensor in Temperature Mode. If the sensor got broken or not
connected well, the machine will give “TEMP SENSOR NOT CONNECTED!” error and
generates an acoustic signal after few seconds of operating and it will turn back to
main menu. If sensor doesn't located properly or part's heat is not increasing then
machine will give “PROBE ERROR!!!” and generates an acoustic signal in two
minutes then it will turn back to main menu.
• You can use magnet sensor to check the workpiece's teperature while operating
the machine in Time Mode.
• Magnet sensor's surface always has to be clean.
• Heated workpiece should not touch the magnet sensor's cable.
• Magnetic sensor always has to be attached to inner ring of the bearing. Otherwise,
it may couse damage on the bearing's surface.
• Magnetic sensor always has to be attached to metal surface because of its
magnetic end. Therefore be sure that metal protect attached to magnetic end or
magnet sensor attached to metal surface when you are not using magnetic sensor.
CAUTION!: Do not use magnet sensor, if you will heat the workpiece over 250 ºC.
That will give a damage to magnet sensor. If you want to heat the workpiece over
250 ºC, please use our special production magnet sensor.
CAUTION!: Always attach the magnet sensor to metal surface or attach metal
protector to magnetic end.
6.4 Operating Modes
FeniX induction heaters can be operated in two different heating modes. In main menu
you will see the Temperature Mode and the Time Mode sections. In Temperature Mode,
the machine generates an acoustic signal and returns to main menu, when tempereture
of the workpiece's reaches to set temperature. In Time Mode, on the other hand, the
machine generates an acoustic signal and returns to main menu, when countdown
finishes. In both modes you can select different power levels during operation.
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6.4.1 Temperature Mode
• Press button 3 to operate the machine in Temperature Mode. Set temperature will
be 110 ºC (the default set temperature for bearing is 110 ºC, if you want to work
with higher temperatures please contact with producer of the bearing).
• To change set temperature, press button 5 and button .6
• If you did not choose power level, choose one of the levels according to guidelines
in section 6.2.
• Be sure that Magnet Sensor placed correctly as shown in section 6.3.
• Press button 7 (ON/OFF) to start operation. When the operation start you will see
the screen below. Your set tempereture will appear next to "TARGET TEMP=" and
you will see the workpiece's temperature next to "PART TEMP=" .
• You can change the set temperature during the operation with pressing button 5
or button 6.
• If you want to stop the oparation before reaching set temperature, press button 7.
Demagnetisation will start automaticly.
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• When workpiece's temperature reaches to set temperature, demagnetisation will
start and you will see the screen below and the machine will generates an acoustic
warning signal for few seconds. The machine will be ready to new operation when
demagnetisation process ends.
• Do not forget that, heated workpiece may cause injuries. Use proper handling
equipment to remove workpiece.
• In the case, the magnet sensor not connected or damaged, you will see the
secreen below then it will turn to manin menu. Try to operate the machine after
checking the magnet sensor.
TEMP SENSOR
NOT CONNECTED!
• If damage on magnet sensor can not be fixed, operate the machine in Time Mode.
Do not forget that, heating bearing without checking its tempereture, can give
damage to bearing.
• If the workpiece's temperature will not increase in 2 minutes, or sensor doesn't
located properly the machine will give “Probe Error !!!” message with acoustic
warning signal then will turn to main menu.
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6.4.2 Time Mode
Caution!: When you are operating the machine in Time Mode, be sure that
the workpiece is not overheated. Overheated workpiece may give
damage to the workpiece and/or the machine.
• In the main menu you will have two different heating modes. Press button 4 to
operate the machine in Time Mode.
5.4TIME MODE
• Set the time with pressing button 5 or button 6 .
• If you did not choose power level, choose one of the levels according to guidelines
in section 6.2.
• If you want to check workpiece's temperature, be sure that Magnet Sensor
connected well and placed correctly as shown in section 6.3.
• Press button 5 (ON/OFF) to start operation. When the operation start you will see
the screen below. Your set time will appear next to "TIME LEFT=" and you will see the
workpiece's temperature next to "PART TEMP="
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• If you want to stop the oparation before reaching set temperature, press button 7.
demagnetisation will start automaticly.
• When coundown finishes, demagnetisation will start and you will see the screen
below and the machine will generates an acoustic signal for few seconds. The
machine will be ready to new operation when demagnetisation process ends
7- Overload Warning
FeniX induction heaters designed to change maximum power level automaticly
depending on workpiece's conductivity and size. Power level can be decreased %2 of
total power. If power level is still over the machine design power, the machine will stop
operating and you will recieve screen below.
OVERLOAD
CHANGE PART!
First Switch Off the machine then Switch it On. If you were working in Turbo Mode, try to
work in Normal Mode. If that will not solve your problem, please contact with us for our
other heater models.
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8- Coil Overheated Warning
Operating the machine out of recommended environments and long operation times
with oversized workpiece or bearings may overheat the induction coil. You will recieve
screen below then the machine will stop operating .Wait for 5 minutes until coil cools
down. Be sure operating environment and workpiece is proper as described in user's
manual section 2.2 and section 3.
COIL
OVERHEATED!
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by
Organize Sanayi Bölgesi
8. cad no:5 Balıkesir
Turkey
Tel: +90266 281 12 21
Fax: +90266 281 12 06
www.fenixheaters.com
www.kanallar.com.tr
Due to a policy of continued development, we reserve the right to alter or amend any
published specification without notice. This document may not be copied, reproduced,
transmitted, modified or used, in whole or in part, without the prior written consent of
KANALLAR Ltd.
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